US20180277535A1 - Normally off iii nitride transistor - Google Patents
Normally off iii nitride transistor Download PDFInfo
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- US20180277535A1 US20180277535A1 US15/988,618 US201815988618A US2018277535A1 US 20180277535 A1 US20180277535 A1 US 20180277535A1 US 201815988618 A US201815988618 A US 201815988618A US 2018277535 A1 US2018277535 A1 US 2018277535A1
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- 150000004767 nitrides Chemical class 0.000 title 1
- 238000000034 method Methods 0.000 claims abstract description 100
- 230000004888 barrier function Effects 0.000 claims abstract description 54
- 239000004065 semiconductor Substances 0.000 claims abstract description 37
- 229910052738 indium Inorganic materials 0.000 claims abstract description 22
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 claims abstract description 22
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 19
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims abstract description 19
- 239000000463 material Substances 0.000 claims description 32
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 23
- 239000002243 precursor Substances 0.000 claims description 21
- 239000000758 substrate Substances 0.000 claims description 17
- GYHNNYVSQQEPJS-UHFFFAOYSA-N Gallium Chemical compound [Ga] GYHNNYVSQQEPJS-UHFFFAOYSA-N 0.000 claims description 11
- 229910052733 gallium Inorganic materials 0.000 claims description 11
- 229910052757 nitrogen Inorganic materials 0.000 claims description 10
- 239000007864 aqueous solution Substances 0.000 claims description 8
- 230000001590 oxidative effect Effects 0.000 claims description 8
- 239000000460 chlorine Substances 0.000 claims description 4
- 229910052801 chlorine Inorganic materials 0.000 claims description 4
- 238000010438 heat treatment Methods 0.000 claims description 4
- PIICEJLVQHRZGT-UHFFFAOYSA-N Ethylenediamine Chemical compound NCCN PIICEJLVQHRZGT-UHFFFAOYSA-N 0.000 claims description 3
- 238000005229 chemical vapour deposition Methods 0.000 claims description 3
- 229910001873 dinitrogen Inorganic materials 0.000 claims 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims 1
- 238000002488 metal-organic chemical vapour deposition Methods 0.000 abstract 3
- 229910002601 GaN Inorganic materials 0.000 description 64
- JMASRVWKEDWRBT-UHFFFAOYSA-N Gallium nitride Chemical compound [Ga]#N JMASRVWKEDWRBT-UHFFFAOYSA-N 0.000 description 61
- QZZYPHBVOQMBAT-JTQLQIEISA-N (2s)-2-amino-3-[4-(2-fluoroethoxy)phenyl]propanoic acid Chemical compound OC(=O)[C@@H](N)CC1=CC=C(OCCF)C=C1 QZZYPHBVOQMBAT-JTQLQIEISA-N 0.000 description 19
- 238000002955 isolation Methods 0.000 description 13
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- 238000004519 manufacturing process Methods 0.000 description 7
- 229910052581 Si3N4 Inorganic materials 0.000 description 6
- KRKNYBCHXYNGOX-UHFFFAOYSA-N citric acid Chemical compound OC(=O)CC(O)(C(O)=O)CC(O)=O KRKNYBCHXYNGOX-UHFFFAOYSA-N 0.000 description 6
- 230000007547 defect Effects 0.000 description 6
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- 238000007254 oxidation reaction Methods 0.000 description 6
- 239000000377 silicon dioxide Substances 0.000 description 6
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- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 6
- JLTRXTDYQLMHGR-UHFFFAOYSA-N trimethylaluminium Chemical compound C[Al](C)C JLTRXTDYQLMHGR-UHFFFAOYSA-N 0.000 description 6
- RNQKDQAVIXDKAG-UHFFFAOYSA-N aluminum gallium Chemical compound [Al].[Ga] RNQKDQAVIXDKAG-UHFFFAOYSA-N 0.000 description 5
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- 239000000203 mixture Substances 0.000 description 4
- XCZXGTMEAKBVPV-UHFFFAOYSA-N trimethylgallium Chemical compound C[Ga](C)C XCZXGTMEAKBVPV-UHFFFAOYSA-N 0.000 description 4
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- 239000012159 carrier gas Substances 0.000 description 3
- 230000005669 field effect Effects 0.000 description 3
- 238000011065 in-situ storage Methods 0.000 description 3
- 238000000623 plasma-assisted chemical vapour deposition Methods 0.000 description 3
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
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- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- 229910018503 SF6 Inorganic materials 0.000 description 2
- 125000004429 atom Chemical group 0.000 description 2
- 229910052796 boron Inorganic materials 0.000 description 2
- HJMZMZRCABDKKV-UHFFFAOYSA-N carbonocyanidic acid Chemical compound OC(=O)C#N HJMZMZRCABDKKV-UHFFFAOYSA-N 0.000 description 2
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- 238000000926 separation method Methods 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- IBEFSUTVZWZJEL-UHFFFAOYSA-N trimethylindium Chemical compound C[In](C)C IBEFSUTVZWZJEL-UHFFFAOYSA-N 0.000 description 2
- KZBUYRJDOAKODT-UHFFFAOYSA-N Chlorine Chemical compound ClCl KZBUYRJDOAKODT-UHFFFAOYSA-N 0.000 description 1
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
- 239000003929 acidic solution Substances 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 238000007743 anodising Methods 0.000 description 1
- NWAIGJYBQQYSPW-UHFFFAOYSA-N azanylidyneindigane Chemical compound [In]#N NWAIGJYBQQYSPW-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- WRQGPGZATPOHHX-UHFFFAOYSA-N ethyl 2-oxohexanoate Chemical compound CCCCC(=O)C(=O)OCC WRQGPGZATPOHHX-UHFFFAOYSA-N 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 229910003437 indium oxide Inorganic materials 0.000 description 1
- PJXISJQVUVHSOJ-UHFFFAOYSA-N indium(iii) oxide Chemical compound [O-2].[O-2].[O-2].[In+3].[In+3] PJXISJQVUVHSOJ-UHFFFAOYSA-N 0.000 description 1
- 238000009616 inductively coupled plasma Methods 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 125000004433 nitrogen atom Chemical group N* 0.000 description 1
- 150000007524 organic acids Chemical class 0.000 description 1
- 239000011368 organic material Substances 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 229920005591 polysilicon Polymers 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- SFZCNBIFKDRMGX-UHFFFAOYSA-N sulfur hexafluoride Chemical compound FS(F)(F)(F)(F)F SFZCNBIFKDRMGX-UHFFFAOYSA-N 0.000 description 1
- 229960000909 sulfur hexafluoride Drugs 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
- VOITXYVAKOUIBA-UHFFFAOYSA-N triethylaluminium Chemical compound CC[Al](CC)CC VOITXYVAKOUIBA-UHFFFAOYSA-N 0.000 description 1
- RGGPNXQUMRMPRA-UHFFFAOYSA-N triethylgallium Chemical compound CC[Ga](CC)CC RGGPNXQUMRMPRA-UHFFFAOYSA-N 0.000 description 1
- OTRPZROOJRIMKW-UHFFFAOYSA-N triethylindigane Chemical compound CC[In](CC)CC OTRPZROOJRIMKW-UHFFFAOYSA-N 0.000 description 1
- 230000005533 two-dimensional electron gas Effects 0.000 description 1
- 238000009827 uniform distribution Methods 0.000 description 1
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- H01L27/04—Devices consisting of a plurality of semiconductor or other solid-state components formed in or on a common substrate including semiconductor components specially adapted for rectifying, oscillating, amplifying or switching and having at least one potential-jump barrier or surface barrier; including integrated passive circuit elements with at least one potential-jump barrier or surface barrier the substrate being a semiconductor body
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- H01L27/0883—Combination of depletion and enhancement field effect transistors
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- H01L29/66462—Unipolar field-effect transistors with an active layer made of a group 13/15 material, e.g. group 13/15 velocity modulation transistor [VMT], group 13/15 negative resistance FET [NERFET] with a heterojunction interface channel or gate, e.g. HFET, HIGFET, SISFET, HJFET, HEMT
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Definitions
- This invention relates to the field of semiconductor devices. More particularly, this invention relates to III-N field effect transistors in semiconductor devices.
- An enhancement mode gallium nitride field effect transistor includes a recessed gate extending into a stressor layer and barrier layer, and vertically separated from a low-doped gallium nitride (GaN) layer.
- GaN gallium nitride
- Forming the gate recess by etching to have a desired vertical separation from the low-doped GaN layer is problematic. Timed etching results in unacceptable variation in the separation from the low-doped GaN layer.
- Forming the gate recess using etch-blocking layers produces defects in the barrier layer and/or the stressor layer.
- a gate recess of the enhancement mode GaN FET extends through the cap layer and the stressor layer, but not through the barrier layer.
- a gate dielectric layer is disposed in the gate recess and a gate is disposed on the gate dielectric layer.
- the semiconductor device is formed by forming the barrier layer with a high temperature metal organic chemical vapor deposition (MOCVD) process, forming the stressor layer with a low temperature MOCVD process and forming the cap layer with a low temperature MOCVD process.
- MOCVD metal organic chemical vapor deposition
- the gate recess is formed by a two-step etch process including a first etch step to remove the cap layer, and a second etch step to remove the stressor layer.
- FIG. 1 is a cross section of an example semiconductor device.
- FIG. 2A through FIG. 2I are cross sections of the semiconductor device of FIG. 1 depicted in successive stages of an example fabrication sequence.
- FIG. 3A and FIG. 3B are cross sections of the semiconductor device of FIG. 1 depicted in an alternate process sequence for forming the gate recess.
- a gate recess of the enhancement mode GaN FET extends through the cap layer and the stressor layer, but not through the barrier layer.
- a gate dielectric layer is disposed in the gate recess and a gate is disposed on the gate dielectric layer.
- the semiconductor device may also include a depletion mode GaN FET with a planar gate over the cap layer and stressor layer.
- a gate dielectric layer and the planar gate of the depletion mode GaN FET may be formed concurrently with the gate dielectric layer and the gate of the enhancement mode GaN FET.
- the semiconductor device is formed by forming the barrier layer with a high temperature MOCVD process, forming the stressor layer with a low temperature MOCVD process and forming the cap layer with a low temperature MOCVD process.
- the gate recess is formed by a two-step etch process including a first etch step to remove the cap layer, and a second etch step to remove the stressor layer.
- the stressor layer may be oxidized by an anodic oxidation process in the gate recess to facilitate removal by the second etch step.
- III-N material is understood to refer to semiconductor materials in which group III elements, that is, aluminum, gallium and indium, and possibly boron, provide a portion of the atoms in the semiconductor material and nitrogen atoms provide the remainder of the atoms in the semiconductor material.
- group III elements that is, aluminum, gallium and indium, and possibly boron
- nitrogen atoms provide the remainder of the atoms in the semiconductor material.
- III-N semiconductor materials are gallium nitride, boron gallium nitride, aluminum gallium nitride, indium nitride, and indium aluminum gallium nitride. Terms such as aluminum gallium nitride describing elemental compositions of materials do not imply a particular stoichiometry of the elements.
- GaN FET is understood to refer to a field effect transistor which includes III-N semiconductor materials.
- FIG. 1 is a cross section of an example semiconductor device.
- the semiconductor device 100 includes an enhancement mode GaN FET 102 and a depletion mode GaN FET 104 .
- the semiconductor device 100 includes a substrate 106 which may be a wafer of silicon or other semiconductor material.
- a buffer layer 108 of III-N material is disposed over the substrate 106 .
- the buffer layer 108 may include for example, 100 to 300 nanometers of aluminum nitride on the substrate 106 and 1 to 7 microns of graded layers of Al x Ga 1-x N which is aluminum rich at a bottom surface, on the aluminum nitride, and gallium rich at a top surface of the buffer layer ( 108 ).
- An electrical isolation layer ( 110 ) is disposed on the buffer layer ( 108 ).
- the electrical isolation layer ( 110 ) may be, for example, 300 to 2000 nanometers of semi-insulating gallium nitride.
- the electrical isolation layer ( 110 ) may be, for example, semi-insulating to provide a desired level of electrical isolation between layers below the electrical isolation layer ( 110 ) and layers above the electrical isolation layer ( 110 ).
- the electrical isolation layer ( 110 ) may be doped with n-type or p-type dopants to reduce undesired effects of charge trapping on current density in the semiconductor device ( 100 ).
- a low-doped layer ( 112 ) is disposed on the electrical isolation layer ( 110 ).
- the low-doped layer ( 112 ) may be, for example, 25 to 1000 nanometers of gallium nitride.
- the low-doped layer ( 112 ) may be formed so as to minimize crystal defects which may have an adverse effect on electron mobility.
- the method of formation of the low-doped layer ( 112 ) may result in the low-doped layer ( 112 ) being doped with carbon, iron or other dopant species, for example with a net doping density less than 10 17 cm ⁇ 3 .
- a barrier layer 114 is disposed over the low-doped layer 112 .
- the barrier layer 114 may be primarily aluminum gallium nitride, with less than 1 atomic percent indium.
- the barrier layer 114 may have a stoichiometry of Al 0.10 Ga 0.90 N to Al 0.30 Ga 0.70 N, and a thickness of 1 nanometers to 5 nanometers.
- a minimum thickness of the barrier layer 114 may be selected to provide ease and reproducibility of fabrication; a maximum thickness may be selected to provide a desired off-state current in the enhancement mode GaN FET 102 , where increasing the thickness of the barrier layer 114 increases the off-state current.
- the thickness may depend on a stoichiometry of the barrier layer 114 .
- an instance of the barrier layer 114 with a stoichiometry of Al 0.10 Ga 0.90 N to Al 0.30 Ga 0.70 N may have a thickness of 1.5 nanometers to 2.0 nanometers.
- a stressor layer 116 is disposed over the barrier layer 114 .
- the stressor layer 116 is primarily indium aluminum nitride, with a stoichiometry of In 0.05 Al 0.95 N to In 0.30 Al 0.70 N, and a thickness of 1 nanometers to 5 nanometers.
- the stressor layer 116 may have a stoichiometry of In 0.16 Al 0.84 N to In 0.18 Al 0.82 N and a thickness of 3.5 nanometers to 4.5 nanometers, which may provide a desired balance between providing a desired charge density in a two-dimensional electron gas (2DEG), which decreases with indium content, and providing a desired etch selectivity to the underlying barrier layer 114 , which increases with indium content.
- the stoichiometry of In 0.16 Al 0.84 N to In 0.18 Al 0.82 N may also provide a desired lattice match to the low-doped layer 112 .
- a cap layer 118 is disposed over the stressor layer 116 .
- the cap layer 118 has less than 1 atomic percent indium, and may be primarily aluminum gallium nitride.
- a thickness of the cap layer is selected to prevent oxidation of the stressor layer 116 during subsequent fabrication steps.
- An example cap layer 118 may have a stoichiometry of Al 0.05 Ga 0.95 N to Al 0.30 Ga 0.70 N, and a thickness of 4 nanometers to 20 nanometers. The cap layer 118 advantageously prevents oxidation of the indium in the stressor layer 116 .
- a gate recess 120 extends through the cap layer 118 and the stressor layer 116 in the enhancement mode GaN FET 102 .
- the gate recess 120 may extend completely through the stressor layer 116 and not extend into the barrier layer 114 , as depicted in FIG. 1 .
- the gate recess 120 may extend partway into the barrier layer 114 , or may extend only partway through the stressor layer 116 and stop short of the barrier layer 114 .
- An enhancement mode gate dielectric layer 122 is disposed in the gate recess 120 in the enhancement mode GaN FET 102 .
- a depletion mode gate dielectric layer 124 is disposed over the cap layer in the depletion mode GaN FET 104 .
- the enhancement mode gate dielectric layer 122 and the depletion mode gate dielectric layer 124 may be 5 nanometers to 50 nanometers thick and may include one or more layers of silicon dioxide, silicon nitride and/or aluminum oxide.
- the enhancement mode gate dielectric layer 122 and the depletion mode gate dielectric layer 124 may have substantially equal thicknesses and compositions, possibly as a result of being formed concurrently.
- the enhancement mode gate dielectric layer 122 and the depletion mode gate dielectric layer 124 may have different thicknesses and compositions, so as to separately optimize performance of the enhancement mode GaN FET 102 and the depletion mode GaN FET 104 .
- a field plate dielectric layer 126 may optionally be disposed over the cap layer 118 and under the enhancement mode gate dielectric layer 122 adjacent to the gate recess 120 and under the depletion mode gate dielectric layer 124 adjacent to a gate area in the depletion mode GaN FET 104 .
- the field plate dielectric layer 126 may include one or more layers of silicon dioxide and/or silicon nitride, and may be, for example, 10 nanometers to 100 nanometers thick. In an alternate version of the instant example, the field plate dielectric layer 126 may be disposed over the enhancement mode gate dielectric layer 122 and the depletion mode gate dielectric layer 124 .
- An enhancement mode gate 128 is disposed over the enhancement mode gate dielectric layer 122 in the gate recess 120 .
- the enhancement mode gate 128 may overlap the field plate dielectric layer 126 in the enhancement mode GaN FET 102 , as depicted in FIG. 1 .
- a depletion mode gate 130 is disposed over the depletion mode gate dielectric layer 124 in the gate area of the depletion mode GaN FET 104 and may overlap the field plate dielectric layer 126 in the depletion mode GaN FET 104 , as depicted in FIG. 1 .
- the enhancement mode gate 128 and the depletion mode gate 130 may have substantially equal compositions, possibly as a result of being formed concurrently.
- Dielectric isolation structures 132 extend through the cap layer 118 , the stressor layer 116 and the barrier layer 114 and possibly through the low-doped layer ( 112 ), so as to laterally isolate the enhancement mode GaN FET ( 102 ) and the depletion mode GaN FET ( 104 ).
- the dielectric isolation structures 132 may include, for example, silicon dioxide and/or silicon nitride.
- a source contact 134 and a drain contact 136 provide electrical connections to a 2DEG in the enhancement mode GaN FET 102 .
- a source contact 138 and a drain contact 140 provide electrical connections to a 2DEG in the depletion mode GaN FET 104 .
- the barrier layer 114 advantageously provides a low carrier density in the 2DEG of the enhancement mode GaN FET 102 under the gate recess 120 , so as to provide a desired off-state current.
- the stressor layer 116 advantageously provides a desired high carrier density in the 2DEG of the enhancement mode GaN FET 102 in the access regions between the gate recess 120 and the source contact 134 and the drain contact 136 , so as to provide a desired on-state current.
- the configuration of the gate recess 120 extending through the stressor layer 116 advantageously contributes to the low carrier density in the 2DEG of the enhancement mode GaN FET 102 under the gate recess 120 .
- the stressor layer 116 extending under the depletion mode gate 130 advantageously provides a desired on-state current in the depletion mode GaN FET 104 .
- FIG. 2A through FIG. 2I are cross sections of the semiconductor device of FIG. 1 depicted in successive stages of an example fabrication sequence.
- the buffer layer 108 is formed over the substrate 106 .
- the electrical isolation layer ( 110 ) is formed over the buffer layer ( 108 ), and the low-doped layer ( 112 ) is formed over the electrical isolation layer ( 110 ).
- the buffer layer 108 , the electrical isolation layer ( 110 ) and the low-doped layer ( 112 ) may be formed, for example, by a series of MOCVD processes.
- the substrate 106 is a 150 millimeter substrate.
- the substrate 106 is placed on a susceptor 142 , possibly of graphite, in an MOCVD chamber 144 .
- the susceptor 142 is heated, for example by heating coils, to a temperature of 900° C. to 1100° C.
- a carrier gas such as hydrogen (H 2 ) as indicated in FIG. 2A is flowed into the MOCVD chamber 144 at a flow rate of 80 standard liters per minute (slm) to 120 slm, and a nitrogen source such as ammonia (NH 3 ) as indicated in FIG.
- TMAl trimethylaluminum
- TMGa trimethylgallium
- a pressure in the MOCVD chamber 144 is maintained at 50 torr to 200 torr.
- the nitrogen source, the aluminum precursor and the gallium precursor react at the existing surface of the semiconductor device 100 to form the barrier layer 114 over the low-doped layer 112 in the areas for the enhancement mode GaN FET 102 and the depletion mode GaN FET 104 .
- Forming the barrier layer 114 at a temperature of 900° C. to 1100° C. advantageously provides fewer defects and hence higher reliability for the semiconductor device 100 compared to a barrier layer formed at a lower temperature.
- substantially no indium precursor is flowed into the MOCVD chamber 144 while the barrier layer 114 is formed.
- the barrier layer 114 may include a quaternary III-N material, that is, may include another element in addition to aluminum, gallium and nitrogen.
- the barrier layer 114 may be formed in situ after the low-doped layer ( 112 ) to advantageously reduce defects in the semiconductor device ( 100 ).
- the substrate 106 remains on the susceptor 142 in the MOCVD chamber 144 .
- the susceptor 142 is heated to a temperature of 700° C. to 850° C.
- a carrier gas, indicated in FIG. 2B as nitrogen (N 2 ) is flowed into the MOCVD chamber 144 at a flow rate of 60 slm to 100 slm, and a nitrogen source, indicated in FIG. 2B as ammonia (NH 3 ), is flowed into the MOCVD chamber 144 at a flow rate of 5 slm to 40 slm.
- TMAl trimethylaluminum
- TMIn trimethylindium
- a pressure in the MOCVD chamber 144 is maintained at 100 torr to 400 torr.
- the nitrogen source, the aluminum precursor and the indium precursor react at the existing surface of the semiconductor device 100 to form the stressor layer 116 over the barrier layer 114 in the areas for the enhancement mode GaN FET 102 and the depletion mode GaN FET 104 .
- Forming the stressor layer 116 at a minimum temperature of 700° C. may advantageously enable a desired concentration of indium and uniform distribution of indium in the stressor layer 116 compared to forming at a lower temperature.
- Forming the stressor layer 116 at a maximum temperature 850° C. may advantageously reduce indium diffusion into the barrier layer 114 compared to forming at a higher temperature.
- substantially no aluminum precursor is flowed into the MOCVD chamber 144 while the stressor layer 116 is formed.
- the stressor layer 116 may include a quaternary III-N material. Forming the stressor layer 116 in situ with the barrier layer 114 may advantageously reduce defects in the semiconductor device ( 100 ).
- the substrate 106 remains on the susceptor 142 in the MOCVD chamber 144 .
- the susceptor 142 is heated to a temperature of 750° C. to 900° C.
- a carrier gas, indicated in FIG. 2C as hydrogen (H 2 ) is flowed into the MOCVD chamber 144 at a flow rate of 80 slm to 120 slm, and a nitrogen source, indicated in FIG. 2C as ammonia (NH 3 ), is flowed into the MOCVD chamber 144 at a flow rate of 5 slm to 35 slm.
- TMAl trimethylaluminum
- MOCVD chamber 144 is flowed into the MOCVD chamber 144 at a rate of 80 sccm to 130 sccm and a gallium precursor, indicated in FIG. 2C as trimethylgallium (TMGa), is flowed into the MOCVD chamber 144 at a rate of 40 sccm to 60 sccm.
- a pressure in the MOCVD chamber 144 is maintained at 50 torr to 200 torr.
- the nitrogen source, the aluminum precursor and the gallium precursor react at the existing surface of the semiconductor device 100 to form the cap layer 118 over the stressor layer 116 in the areas for the enhancement mode GaN FET 102 and the depletion mode GaN FET 104 .
- Forming the cap layer 118 at a maximum temperature of 900° C. may advantageously reduce indium diffusion into the barrier layer 114 and the cap layer 118 compared to forming at a higher temperature.
- substantially no indium precursor is flowed into the MOCVD chamber 144 while the cap layer 118 is formed.
- the cap layer 118 may be formed in situ after the stressor layer ( 116 ) to advantageously reduce defects in the semiconductor device ( 100 ).
- the field plate dielectric layer 126 is formed over the cap layer 118 .
- the field plate dielectric layer 126 may be formed, for example, by forming a layer of dielectric material containing silicon dioxide and/or silicon nitride over the cap layer by a plasma enhanced chemical vapor deposition (PECVD) process.
- PECVD plasma enhanced chemical vapor deposition
- a field plate mask 146 is formed over the layer of dielectric material so as to expose gate areas for the enhancement mode GaN FET 102 and the depletion mode GaN FET 104 .
- the layer of dielectric material is removed where exposed by the field plate mask 146 by an etch process such as a plasma etch process at over 100 torr, forming the field plate dielectric layer 126 with sloped sides as depicted in FIG. 2D .
- a recess mask 148 is formed over the cap layer 118 to expose an area in the enhancement mode GaN FET 102 for the gate recess 120 .
- the recess mask 148 may include photoresist and may be formed by a photolithographic process.
- the recess mask 148 may further include an antireflection layer such as an organic bottom antireflection coating (BARC) and/or a hard mask layer such as silicon dioxide or silicon nitride.
- BARC organic bottom antireflection coating
- the recess mask 148 covers the area for the depletion mode GaN FET 104 .
- a first etch process 150 such as a plasma etch process using chlorine radicals removes the cap layer 118 in the area exposed by the recess mask 148 to form a portion of the gate recess 120 .
- the indium in the stressor layer 116 has a lower etch rate in the first etch process 150 than the cap layer 118 , so at least a portion of the stressor layer 116 remains in the area for the gate recess 120 after the first etch process 150 is completed.
- the first etch process 150 may be, for example, an inductively-coupled plasma reactive ion etch (ICP-RIE) process using chlorine (Cl 2 ) gas sulfur hexafluoride (SF 6 ) gas, which has been demonstrated to desirably provide an etch selectivity of gallium aluminum nitride to indium aluminum nitride greater than 1.0.
- ICP-RIE inductively-coupled plasma reactive ion etch
- SF 6 sulfur hexafluoride
- a second etch process 152 removes the stressor layer 116 in the gate recess 120 to form the complete gate recess 120 .
- the second etch process 152 has a different chemistry than the first etch process 150 of FIG. 2E .
- the barrier layer 114 has a lower etch rate in the second etch process 152 than the stressor layer 116 , so at least a portion, and possibly all, of the barrier layer 114 remains under the gate recess 120 after the second etch process 152 is completed.
- the second etch process 152 may include, for example, a wet etch process using a 1 molar aqueous solution of 1,2 diaminoethane, which has been demonstrated to desirable provide an etch selectivity of indium aluminum nitride to gallium aluminum nitride eater than 1.0 at room temperature.
- the first etch process 150 may provide a desirably rough surface on the exposed stressor layer 116 which may advantageously provide a more uniform initial etch rate for the second etch process 152 .
- a remaining portion 154 of the stressor layer 116 in the gate recess 120 may be a transition layer 154 which includes elements of the underlying barrier layer 114 .
- An oxidizing liquid 156 oxidizes the remaining portion 154 of the stressor layer 116 in the gate recess 120 .
- the remaining portion 154 of the stressor layer 116 may be oxidized by an anodic oxidation process in which electrical current is passed through the oxidizing liquid 156 .
- the oxidizing liquid 156 may be an aqueous solution of nitriloacetic acid and 0.3 molar potassium hydroxide (KOH) with a pH value of 8.5.
- the electrical current may have a value of about 20 microamperes per square centimeter of exposed stressor layer 116 .
- the oxidized remaining portion 154 may be subsequently removed, for example by a wet etch process using a dilute aqueous acidic solution, such as a dilute nitric acid solution or a citric acid solution.
- the recess mask 148 is removed, possibly after the wet etch process 152 of FIG. 2F is completed, or possibly earlier.
- a layer of gate dielectric material 158 is formed over the field plate dielectric layer 126 , extending into the gate recess 120 and overlying the barrier layer 114 at a bottom of the gate recess 120 .
- the layer of gate dielectric material 158 extends over the cap layer 118 in the depletion mode GaN FET 104 .
- the layer of gate dielectric material 158 may include one or more layers of silicon dioxide and/or silicon nitride, formed, for example, by PECVD processes.
- a layer of gate material 160 is formed over the layer of gate dielectric material 158 .
- the layer of gate material 160 may include, for example, gallium nitride or other III-N material, or may include polycrystalline silicon, referred to as polysilicon, or may include metal.
- the layer of gate material 160 is formed in the areas for the gates of both the enhancement mode GaN FET 102 and the depletion mode GaN FET 104 .
- the layer of gate material 160 of FIG. 2H is patterned to concurrently form the enhancement mode gate 128 and the depletion mode gate 130 .
- the enhancement mode gate 128 and the depletion mode gate 130 may be formed by an etch process: forming an etch mask over the layer of gate material 160 which covers area for the enhancement mode gate 128 and the depletion mode gate 130 , and subsequently removing the layer of gate material 160 where exposed by the etch mask.
- the enhancement mode gate 128 and the depletion mode gate 130 may be formed by a liftoff process: forming a liftoff mask of solvent-soluble organic material such as photoresist which exposes the layer of gate dielectric material 158 in the areas for the enhancement mode gate 128 and the depletion mode gate 130 , forming the layer of gate material 160 over the liftoff mask, and subsequently removing the liftoff mask and the overlying layer of gate material 160 , leaving the layer of gate material 160 in the areas exposed by the liftoff mask to provide the enhancement mode gate 128 and the depletion mode gate 130 .
- Forming the enhancement mode gate 128 and the depletion mode gate 130 concurrently may advantageously reduce fabrication cost and complexity of the semiconductor device 100 .
- the enhancement mode gate 128 and the depletion mode gate 130 may be formed separately, of materials with different work functions, to increase performance of both the enhancement mode GaN FET 102 and the depletion mode GaN FET 104 .
- fabrication is continued to provide the structure of FIG. 1 .
- FIG. 3A and FIG. 3B are cross sections of the semiconductor device of FIG. 1 depicted in an alternate process sequence for forming the gate recess.
- the recess mask 148 is formed over the cap layer 118 .
- the cap layer 118 is removed in the area exposed by the recess mask 148 to form a portion of the gate recess 120 , as described in reference to FIG. 2E .
- An oxidizing liquid 162 for example an anodizing aqueous solution containing an aqueous solution of nitriloacetic acid and 0.3 molar KOH with a pH value of 8.5 with an electrical current of about 20 microamperes per square centimeter of exposed stressor layer 116 , oxidizes the stressor layer 116 where exposed by the cap layer 118 in the gate recess 120 to form an oxidized stressor layer 164 which includes indium oxide.
- the barrier layer 114 may include a layer of gallium nitride (GaN) 1 nanometer to 3 nanometers thick immediately below the stressor layer 116 to prevent oxidation of the aluminum gallium nitride in the barrier layer 114 . At least a portion of the barrier layer 114 under the stressor layer 116 in the gate recess 120 is not oxidized.
- a second etch process 166 removes the oxidized stressor layer 164 of FIG. 3A to form the gate recess 120 , while leaving at least a portion, and possibly all, of the barrier layer 114 under the gate recess 120 .
- the second etch process 166 may include, for example, a dilute aqueous solution of nitric acid, phosphoric acid, and/or hydrochloric acid, or an aqueous solution of an organic acid such as citric acid.
- the oxidation process described in reference to FIG. 3A and the second etch process of FIG. 3B may be repeated to completely remove the stressor layer 116 from the gate recess 120 .
- the recess mask 148 is removed and fabrication is continued as described in reference to FIG. 2G .
Abstract
Description
- This application is a divisional of U.S. Nonprovisional patent application Ser. No. 14/673,844, filed Mar. 30, 2015, the contents of which is herein incorporated by reference in its entirety.
- This invention relates to the field of semiconductor devices. More particularly, this invention relates to III-N field effect transistors in semiconductor devices.
- An enhancement mode gallium nitride field effect transistor (GaN FET) includes a recessed gate extending into a stressor layer and barrier layer, and vertically separated from a low-doped gallium nitride (GaN) layer. Forming the gate recess by etching to have a desired vertical separation from the low-doped GaN layer is problematic. Timed etching results in unacceptable variation in the separation from the low-doped GaN layer. Forming the gate recess using etch-blocking layers produces defects in the barrier layer and/or the stressor layer.
- The following presents a simplified summary in order to provide a basic understanding of one or more aspects of the invention. This summary is not an extensive overview of the invention, and is neither intended to identify key or critical elements of the invention, nor to delineate the scope thereof. Rather, the primary purpose of the summary is to present some concepts of the invention in a simplified form as a prelude to a more detailed description that is presented later.
- A semiconductor device containing an enhancement mode GaN FET on a III-N layer stack including a low-doped GaN layer, a barrier layer including aluminum disposed over the low-doped GaN layer, a stressor layer including indium disposed over the barrier layer, and a cap layer including aluminum disposed over the stressor layer. A gate recess of the enhancement mode GaN FET extends through the cap layer and the stressor layer, but not through the barrier layer. A gate dielectric layer is disposed in the gate recess and a gate is disposed on the gate dielectric layer.
- The semiconductor device is formed by forming the barrier layer with a high temperature metal organic chemical vapor deposition (MOCVD) process, forming the stressor layer with a low temperature MOCVD process and forming the cap layer with a low temperature MOCVD process. The gate recess is formed by a two-step etch process including a first etch step to remove the cap layer, and a second etch step to remove the stressor layer.
-
FIG. 1 is a cross section of an example semiconductor device. -
FIG. 2A throughFIG. 2I are cross sections of the semiconductor device ofFIG. 1 depicted in successive stages of an example fabrication sequence. -
FIG. 3A andFIG. 3B are cross sections of the semiconductor device ofFIG. 1 depicted in an alternate process sequence for forming the gate recess. - The present invention is described with reference to the attached figures. The figures are not drawn to scale and they are provided merely to illustrate the invention. Several aspects of the invention are described below with reference to example applications for illustration. It should be understood that numerous specific details, relationships, and methods are set forth to provide an understanding of the invention. One skilled in the relevant art, however, will readily recognize that the invention can be practiced without one or more of the specific details or with other methods. In other instances, well-known structures or operations are not shown in detail to avoid obscuring the invention. The present invention is not limited by the illustrated ordering of acts or events, as some acts may occur in different orders and/or concurrently with other acts or events. Furthermore, not all illustrated acts or events are required to implement a methodology in accordance with the present invention.
- A semiconductor device containing an enhancement mode GaN FET on a III-N layer stack including a low-doped GaN layer, a barrier layer including aluminum disposed over the low-doped GaN layer, a stressor layer including indium disposed over the barrier layer, and a cap layer including aluminum disposed over the stressor layer. A gate recess of the enhancement mode GaN FET extends through the cap layer and the stressor layer, but not through the barrier layer. A gate dielectric layer is disposed in the gate recess and a gate is disposed on the gate dielectric layer.
- The semiconductor device may also include a depletion mode GaN FET with a planar gate over the cap layer and stressor layer. A gate dielectric layer and the planar gate of the depletion mode GaN FET may be formed concurrently with the gate dielectric layer and the gate of the enhancement mode GaN FET.
- The semiconductor device is formed by forming the barrier layer with a high temperature MOCVD process, forming the stressor layer with a low temperature MOCVD process and forming the cap layer with a low temperature MOCVD process. The gate recess is formed by a two-step etch process including a first etch step to remove the cap layer, and a second etch step to remove the stressor layer. The stressor layer may be oxidized by an anodic oxidation process in the gate recess to facilitate removal by the second etch step.
- For the purposes of this description, the term “III-N material” is understood to refer to semiconductor materials in which group III elements, that is, aluminum, gallium and indium, and possibly boron, provide a portion of the atoms in the semiconductor material and nitrogen atoms provide the remainder of the atoms in the semiconductor material. Examples of III-N semiconductor materials are gallium nitride, boron gallium nitride, aluminum gallium nitride, indium nitride, and indium aluminum gallium nitride. Terms such as aluminum gallium nitride describing elemental compositions of materials do not imply a particular stoichiometry of the elements. For the purposes of this description, the term GaN FET is understood to refer to a field effect transistor which includes III-N semiconductor materials.
-
FIG. 1 is a cross section of an example semiconductor device. Thesemiconductor device 100 includes an enhancement mode GaN FET 102 and a depletion mode GaN FET 104. Thesemiconductor device 100 includes asubstrate 106 which may be a wafer of silicon or other semiconductor material. Abuffer layer 108 of III-N material is disposed over thesubstrate 106. Thebuffer layer 108 may include for example, 100 to 300 nanometers of aluminum nitride on thesubstrate 106 and 1 to 7 microns of graded layers of AlxGa1-xN which is aluminum rich at a bottom surface, on the aluminum nitride, and gallium rich at a top surface of the buffer layer (108). An electrical isolation layer (110) is disposed on the buffer layer (108). The electrical isolation layer (110) may be, for example, 300 to 2000 nanometers of semi-insulating gallium nitride. The electrical isolation layer (110) may be, for example, semi-insulating to provide a desired level of electrical isolation between layers below the electrical isolation layer (110) and layers above the electrical isolation layer (110). Alternatively, the electrical isolation layer (110) may be doped with n-type or p-type dopants to reduce undesired effects of charge trapping on current density in the semiconductor device (100). A low-doped layer (112) is disposed on the electrical isolation layer (110). The low-doped layer (112) may be, for example, 25 to 1000 nanometers of gallium nitride. The low-doped layer (112) may be formed so as to minimize crystal defects which may have an adverse effect on electron mobility. The method of formation of the low-doped layer (112) may result in the low-doped layer (112) being doped with carbon, iron or other dopant species, for example with a net doping density less than 1017 cm−3. - A
barrier layer 114 is disposed over the low-dopedlayer 112. Thebarrier layer 114 may be primarily aluminum gallium nitride, with less than 1 atomic percent indium. Thebarrier layer 114 may have a stoichiometry of Al0.10Ga0.90N to Al0.30Ga0.70N, and a thickness of 1 nanometers to 5 nanometers. A minimum thickness of thebarrier layer 114 may be selected to provide ease and reproducibility of fabrication; a maximum thickness may be selected to provide a desired off-state current in the enhancementmode GaN FET 102, where increasing the thickness of thebarrier layer 114 increases the off-state current. The thickness may depend on a stoichiometry of thebarrier layer 114. For example, an instance of thebarrier layer 114 with a stoichiometry of Al0.10Ga0.90N to Al0.30Ga0.70N may have a thickness of 1.5 nanometers to 2.0 nanometers. - A
stressor layer 116 is disposed over thebarrier layer 114. Thestressor layer 116 is primarily indium aluminum nitride, with a stoichiometry of In0.05Al0.95N to In0.30Al0.70N, and a thickness of 1 nanometers to 5 nanometers. In one version of the instant example, thestressor layer 116 may have a stoichiometry of In0.16Al0.84N to In0.18Al0.82N and a thickness of 3.5 nanometers to 4.5 nanometers, which may provide a desired balance between providing a desired charge density in a two-dimensional electron gas (2DEG), which decreases with indium content, and providing a desired etch selectivity to theunderlying barrier layer 114, which increases with indium content. The stoichiometry of In0.16Al0.84N to In0.18Al0.82N may also provide a desired lattice match to the low-dopedlayer 112. - A
cap layer 118 is disposed over thestressor layer 116. Thecap layer 118 has less than 1 atomic percent indium, and may be primarily aluminum gallium nitride. A thickness of the cap layer is selected to prevent oxidation of thestressor layer 116 during subsequent fabrication steps. Anexample cap layer 118 may have a stoichiometry of Al0.05Ga0.95N to Al0.30Ga0.70N, and a thickness of 4 nanometers to 20 nanometers. Thecap layer 118 advantageously prevents oxidation of the indium in thestressor layer 116. - A
gate recess 120 extends through thecap layer 118 and thestressor layer 116 in the enhancementmode GaN FET 102. Thegate recess 120 may extend completely through thestressor layer 116 and not extend into thebarrier layer 114, as depicted inFIG. 1 . Alternatively, thegate recess 120 may extend partway into thebarrier layer 114, or may extend only partway through thestressor layer 116 and stop short of thebarrier layer 114. - An enhancement mode
gate dielectric layer 122 is disposed in thegate recess 120 in the enhancementmode GaN FET 102. A depletion modegate dielectric layer 124 is disposed over the cap layer in the depletionmode GaN FET 104. The enhancement modegate dielectric layer 122 and the depletion modegate dielectric layer 124 may be 5 nanometers to 50 nanometers thick and may include one or more layers of silicon dioxide, silicon nitride and/or aluminum oxide. In one version of the instant example, the enhancement modegate dielectric layer 122 and the depletion modegate dielectric layer 124 may have substantially equal thicknesses and compositions, possibly as a result of being formed concurrently. In an alternate version, the enhancement modegate dielectric layer 122 and the depletion modegate dielectric layer 124 may have different thicknesses and compositions, so as to separately optimize performance of the enhancementmode GaN FET 102 and the depletionmode GaN FET 104. - A field
plate dielectric layer 126 may optionally be disposed over thecap layer 118 and under the enhancement modegate dielectric layer 122 adjacent to thegate recess 120 and under the depletion modegate dielectric layer 124 adjacent to a gate area in the depletionmode GaN FET 104. The fieldplate dielectric layer 126 may include one or more layers of silicon dioxide and/or silicon nitride, and may be, for example, 10 nanometers to 100 nanometers thick. In an alternate version of the instant example, the fieldplate dielectric layer 126 may be disposed over the enhancement modegate dielectric layer 122 and the depletion modegate dielectric layer 124. - An
enhancement mode gate 128 is disposed over the enhancement modegate dielectric layer 122 in thegate recess 120. Theenhancement mode gate 128 may overlap the fieldplate dielectric layer 126 in the enhancementmode GaN FET 102, as depicted inFIG. 1 . Adepletion mode gate 130 is disposed over the depletion modegate dielectric layer 124 in the gate area of the depletionmode GaN FET 104 and may overlap the fieldplate dielectric layer 126 in the depletionmode GaN FET 104, as depicted inFIG. 1 . Theenhancement mode gate 128 and thedepletion mode gate 130 may have substantially equal compositions, possibly as a result of being formed concurrently. -
Dielectric isolation structures 132 extend through thecap layer 118, thestressor layer 116 and thebarrier layer 114 and possibly through the low-doped layer (112), so as to laterally isolate the enhancement mode GaN FET (102) and the depletion mode GaN FET (104). Thedielectric isolation structures 132 may include, for example, silicon dioxide and/or silicon nitride. - A
source contact 134 and adrain contact 136 provide electrical connections to a 2DEG in the enhancementmode GaN FET 102. Asource contact 138 and adrain contact 140 provide electrical connections to a 2DEG in the depletionmode GaN FET 104. - During operation of the
semiconductor device 100, thebarrier layer 114 advantageously provides a low carrier density in the 2DEG of the enhancementmode GaN FET 102 under thegate recess 120, so as to provide a desired off-state current. Thestressor layer 116 advantageously provides a desired high carrier density in the 2DEG of the enhancementmode GaN FET 102 in the access regions between thegate recess 120 and thesource contact 134 and thedrain contact 136, so as to provide a desired on-state current. The configuration of thegate recess 120 extending through thestressor layer 116 advantageously contributes to the low carrier density in the 2DEG of the enhancementmode GaN FET 102 under thegate recess 120. Thestressor layer 116 extending under thedepletion mode gate 130 advantageously provides a desired on-state current in the depletionmode GaN FET 104. -
FIG. 2A throughFIG. 2I are cross sections of the semiconductor device ofFIG. 1 depicted in successive stages of an example fabrication sequence. Referring toFIG. 2A , thebuffer layer 108 is formed over thesubstrate 106. The electrical isolation layer (110) is formed over the buffer layer (108), and the low-doped layer (112) is formed over the electrical isolation layer (110). Thebuffer layer 108, the electrical isolation layer (110) and the low-doped layer (112) may be formed, for example, by a series of MOCVD processes. - In the instant example, process parameters will be described for a case wherein the
substrate 106 is a 150 millimeter substrate. Thesubstrate 106 is placed on asusceptor 142, possibly of graphite, in anMOCVD chamber 144. Thesusceptor 142 is heated, for example by heating coils, to a temperature of 900° C. to 1100° C. A carrier gas such as hydrogen (H2) as indicated inFIG. 2A is flowed into theMOCVD chamber 144 at a flow rate of 80 standard liters per minute (slm) to 120 slm, and a nitrogen source such as ammonia (NH3) as indicated inFIG. 2A is flowed into theMOCVD chamber 144 at a flow rate of 5 slm to 30 slm. An aluminum precursor such as trimethylaluminum (TMAl) as indicated inFIG. 2A , or triethylaluminum, is flowed into theMOCVD chamber 144 at a rate of 80 standard cubic centimeters per minute (sccm) to 130 sccm and a gallium precursor such as trimethylgallium (TMGa) as indicated inFIG. 2A , or triethylgallium, is flowed into theMOCVD chamber 144 at a rate of 40 sccm to 60 sccm. A pressure in theMOCVD chamber 144 is maintained at 50 torr to 200 torr. The nitrogen source, the aluminum precursor and the gallium precursor react at the existing surface of thesemiconductor device 100 to form thebarrier layer 114 over the low-dopedlayer 112 in the areas for the enhancementmode GaN FET 102 and the depletionmode GaN FET 104. Forming thebarrier layer 114 at a temperature of 900° C. to 1100° C. advantageously provides fewer defects and hence higher reliability for thesemiconductor device 100 compared to a barrier layer formed at a lower temperature. In the instant example, substantially no indium precursor is flowed into theMOCVD chamber 144 while thebarrier layer 114 is formed. In an alternate version of the instant example, thebarrier layer 114 may include a quaternary III-N material, that is, may include another element in addition to aluminum, gallium and nitrogen. Thebarrier layer 114 may be formed in situ after the low-doped layer (112) to advantageously reduce defects in the semiconductor device (100). - Referring to
FIG. 2B , thesubstrate 106 remains on thesusceptor 142 in theMOCVD chamber 144. Thesusceptor 142 is heated to a temperature of 700° C. to 850° C. A carrier gas, indicated inFIG. 2B as nitrogen (N2), is flowed into theMOCVD chamber 144 at a flow rate of 60 slm to 100 slm, and a nitrogen source, indicated inFIG. 2B as ammonia (NH3), is flowed into theMOCVD chamber 144 at a flow rate of 5 slm to 40 slm. An aluminum precursor, indicated inFIG. 2B as trimethylaluminum (TMAl), is flowed into theMOCVD chamber 144 at a rate of 80 sccm to 130 sccm and an indium precursor such as trimethylindium (TMIn) as indicated inFIG. 2B , or triethylindium, is flowed into theMOCVD chamber 144 at a rate of 100 sccm to 300 sccm. A pressure in theMOCVD chamber 144 is maintained at 100 torr to 400 torr. The nitrogen source, the aluminum precursor and the indium precursor react at the existing surface of thesemiconductor device 100 to form thestressor layer 116 over thebarrier layer 114 in the areas for the enhancementmode GaN FET 102 and the depletionmode GaN FET 104. Forming thestressor layer 116 at a minimum temperature of 700° C. may advantageously enable a desired concentration of indium and uniform distribution of indium in thestressor layer 116 compared to forming at a lower temperature. Forming thestressor layer 116 at a maximum temperature 850° C. may advantageously reduce indium diffusion into thebarrier layer 114 compared to forming at a higher temperature. In the instant example, substantially no aluminum precursor is flowed into theMOCVD chamber 144 while thestressor layer 116 is formed. In an alternate version of the instant example, thestressor layer 116 may include a quaternary III-N material. Forming thestressor layer 116 in situ with thebarrier layer 114 may advantageously reduce defects in the semiconductor device (100). - Referring to
FIG. 2C , thesubstrate 106 remains on thesusceptor 142 in theMOCVD chamber 144. Thesusceptor 142 is heated to a temperature of 750° C. to 900° C. A carrier gas, indicated inFIG. 2C as hydrogen (H2), is flowed into theMOCVD chamber 144 at a flow rate of 80 slm to 120 slm, and a nitrogen source, indicated inFIG. 2C as ammonia (NH3), is flowed into theMOCVD chamber 144 at a flow rate of 5 slm to 35 slm. An aluminum precursor, indicated inFIG. 2C as trimethylaluminum (TMAl), is flowed into theMOCVD chamber 144 at a rate of 80 sccm to 130 sccm and a gallium precursor, indicated inFIG. 2C as trimethylgallium (TMGa), is flowed into theMOCVD chamber 144 at a rate of 40 sccm to 60 sccm. A pressure in theMOCVD chamber 144 is maintained at 50 torr to 200 torr. The nitrogen source, the aluminum precursor and the gallium precursor react at the existing surface of thesemiconductor device 100 to form thecap layer 118 over thestressor layer 116 in the areas for the enhancementmode GaN FET 102 and the depletionmode GaN FET 104. Forming thecap layer 118 at a maximum temperature of 900° C. may advantageously reduce indium diffusion into thebarrier layer 114 and thecap layer 118 compared to forming at a higher temperature. In the instant example, substantially no indium precursor is flowed into theMOCVD chamber 144 while thecap layer 118 is formed. Thecap layer 118 may be formed in situ after the stressor layer (116) to advantageously reduce defects in the semiconductor device (100). - Referring to
FIG. 2D , the fieldplate dielectric layer 126 is formed over thecap layer 118. The fieldplate dielectric layer 126 may be formed, for example, by forming a layer of dielectric material containing silicon dioxide and/or silicon nitride over the cap layer by a plasma enhanced chemical vapor deposition (PECVD) process. Afield plate mask 146 is formed over the layer of dielectric material so as to expose gate areas for the enhancementmode GaN FET 102 and the depletionmode GaN FET 104. The layer of dielectric material is removed where exposed by thefield plate mask 146 by an etch process such as a plasma etch process at over 100 torr, forming the fieldplate dielectric layer 126 with sloped sides as depicted inFIG. 2D . - Referring to
FIG. 2E , arecess mask 148 is formed over thecap layer 118 to expose an area in the enhancementmode GaN FET 102 for thegate recess 120. Therecess mask 148 may include photoresist and may be formed by a photolithographic process. Therecess mask 148 may further include an antireflection layer such as an organic bottom antireflection coating (BARC) and/or a hard mask layer such as silicon dioxide or silicon nitride. Therecess mask 148 covers the area for the depletionmode GaN FET 104. - A
first etch process 150 such as a plasma etch process using chlorine radicals removes thecap layer 118 in the area exposed by therecess mask 148 to form a portion of thegate recess 120. The indium in thestressor layer 116 has a lower etch rate in thefirst etch process 150 than thecap layer 118, so at least a portion of thestressor layer 116 remains in the area for thegate recess 120 after thefirst etch process 150 is completed. Thefirst etch process 150 may be, for example, an inductively-coupled plasma reactive ion etch (ICP-RIE) process using chlorine (Cl2) gas sulfur hexafluoride (SF6) gas, which has been demonstrated to desirably provide an etch selectivity of gallium aluminum nitride to indium aluminum nitride greater than 1.0. Forming thecap layer 118 at a maximum temperature of 900° C., in combination with the indium content in thestressor layer 116, may advantageously increase the etch selectivity for thefirst etch process 150 so as to reduce the amount, if any, of thestressor layer 116 removed by thefirst etch process 150. - Referring to
FIG. 2F , asecond etch process 152 removes thestressor layer 116 in thegate recess 120 to form thecomplete gate recess 120. Thesecond etch process 152 has a different chemistry than thefirst etch process 150 ofFIG. 2E . Thebarrier layer 114 has a lower etch rate in thesecond etch process 152 than thestressor layer 116, so at least a portion, and possibly all, of thebarrier layer 114 remains under thegate recess 120 after thesecond etch process 152 is completed. Thesecond etch process 152 may include, for example, a wet etch process using a 1 molar aqueous solution of 1,2 diaminoethane, which has been demonstrated to desirable provide an etch selectivity of indium aluminum nitride to gallium aluminum nitride eater than 1.0 at room temperature. Thefirst etch process 150 may provide a desirably rough surface on the exposedstressor layer 116 which may advantageously provide a more uniform initial etch rate for thesecond etch process 152. - Referring to
FIG. 2G , there may be a remainingportion 154 of thestressor layer 116 in thegate recess 120, possibly atransition layer 154 which includes elements of theunderlying barrier layer 114. An oxidizingliquid 156 oxidizes the remainingportion 154 of thestressor layer 116 in thegate recess 120. The remainingportion 154 of thestressor layer 116 may be oxidized by an anodic oxidation process in which electrical current is passed through the oxidizingliquid 156. For example, the oxidizingliquid 156 may be an aqueous solution of nitriloacetic acid and 0.3 molar potassium hydroxide (KOH) with a pH value of 8.5. The electrical current may have a value of about 20 microamperes per square centimeter of exposedstressor layer 116. The oxidized remainingportion 154 may be subsequently removed, for example by a wet etch process using a dilute aqueous acidic solution, such as a dilute nitric acid solution or a citric acid solution. Therecess mask 148 is removed, possibly after thewet etch process 152 ofFIG. 2F is completed, or possibly earlier. - Referring to
FIG. 2H , a layer of gatedielectric material 158 is formed over the fieldplate dielectric layer 126, extending into thegate recess 120 and overlying thebarrier layer 114 at a bottom of thegate recess 120. In the instant example, the layer of gatedielectric material 158 extends over thecap layer 118 in the depletionmode GaN FET 104. The layer of gatedielectric material 158 may include one or more layers of silicon dioxide and/or silicon nitride, formed, for example, by PECVD processes. A layer ofgate material 160 is formed over the layer of gatedielectric material 158. The layer ofgate material 160 may include, for example, gallium nitride or other III-N material, or may include polycrystalline silicon, referred to as polysilicon, or may include metal. In the instant example, the layer ofgate material 160 is formed in the areas for the gates of both the enhancementmode GaN FET 102 and the depletionmode GaN FET 104. - Referring to
FIG. 2I , the layer ofgate material 160 ofFIG. 2H is patterned to concurrently form theenhancement mode gate 128 and thedepletion mode gate 130. Theenhancement mode gate 128 and thedepletion mode gate 130 may be formed by an etch process: forming an etch mask over the layer ofgate material 160 which covers area for theenhancement mode gate 128 and thedepletion mode gate 130, and subsequently removing the layer ofgate material 160 where exposed by the etch mask. Alternatively, theenhancement mode gate 128 and thedepletion mode gate 130 may be formed by a liftoff process: forming a liftoff mask of solvent-soluble organic material such as photoresist which exposes the layer of gatedielectric material 158 in the areas for theenhancement mode gate 128 and thedepletion mode gate 130, forming the layer ofgate material 160 over the liftoff mask, and subsequently removing the liftoff mask and the overlying layer ofgate material 160, leaving the layer ofgate material 160 in the areas exposed by the liftoff mask to provide theenhancement mode gate 128 and thedepletion mode gate 130. Forming theenhancement mode gate 128 and thedepletion mode gate 130 concurrently may advantageously reduce fabrication cost and complexity of thesemiconductor device 100. In an alternate version of the instant example, theenhancement mode gate 128 and thedepletion mode gate 130 may be formed separately, of materials with different work functions, to increase performance of both the enhancementmode GaN FET 102 and the depletionmode GaN FET 104. After forming the enhancementmode GaN FET 102 and the depletionmode GaN FET 104, fabrication is continued to provide the structure ofFIG. 1 . -
FIG. 3A andFIG. 3B are cross sections of the semiconductor device ofFIG. 1 depicted in an alternate process sequence for forming the gate recess. Referring toFIG. 3A , therecess mask 148 is formed over thecap layer 118. Thecap layer 118 is removed in the area exposed by therecess mask 148 to form a portion of thegate recess 120, as described in reference toFIG. 2E . An oxidizingliquid 162, for example an anodizing aqueous solution containing an aqueous solution of nitriloacetic acid and 0.3 molar KOH with a pH value of 8.5 with an electrical current of about 20 microamperes per square centimeter of exposedstressor layer 116, oxidizes thestressor layer 116 where exposed by thecap layer 118 in thegate recess 120 to form anoxidized stressor layer 164 which includes indium oxide. In the instant example, thebarrier layer 114 may include a layer of gallium nitride (GaN) 1 nanometer to 3 nanometers thick immediately below thestressor layer 116 to prevent oxidation of the aluminum gallium nitride in thebarrier layer 114. At least a portion of thebarrier layer 114 under thestressor layer 116 in thegate recess 120 is not oxidized. - Referring to
FIG. 3B , asecond etch process 166 removes theoxidized stressor layer 164 ofFIG. 3A to form thegate recess 120, while leaving at least a portion, and possibly all, of thebarrier layer 114 under thegate recess 120. Thesecond etch process 166 may include, for example, a dilute aqueous solution of nitric acid, phosphoric acid, and/or hydrochloric acid, or an aqueous solution of an organic acid such as citric acid. The oxidation process described in reference toFIG. 3A and the second etch process ofFIG. 3B may be repeated to completely remove thestressor layer 116 from thegate recess 120. Therecess mask 148 is removed and fabrication is continued as described in reference toFIG. 2G . - While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only and not limitation. Numerous changes to the disclosed embodiments can be made in accordance with the disclosure herein without departing from the spirit or scope of the invention. Thus, the breadth and scope of the present invention should not be limited by any of the above described embodiments. Rather, the scope of the invention should be defined in accordance with the following claims and their equivalents.
Claims (18)
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